U.S. patent application number 11/055924 was filed with the patent office on 2009-06-04 for mobile hand-held laser welding support system.
This patent application is currently assigned to Honeywell International, Inc.. Invention is credited to Martin C. Baker, William F. Hehmann, Clyde R. Taylor.
Application Number | 20090139967 11/055924 |
Document ID | / |
Family ID | 38309635 |
Filed Date | 2009-06-04 |
United States Patent
Application |
20090139967 |
Kind Code |
A1 |
Baker; Martin C. ; et
al. |
June 4, 2009 |
MOBILE HAND-HELD LASER WELDING SUPPORT SYSTEM
Abstract
A mobile support system for a hand-held laser welding wand
includes a movable cart, a laser source, a fluid source, and a
filler medium supply source. The laser source is mounted on the
movable cart and is configured to supply laser light for the
hand-held laser welding wand. The fluid source is mounted on the
movable cart and is configured to supply cooling fluid for the
hand-held laser welding wand. The filler medium supply source is
mounted on the movable cart and is configured to supply a filler
medium for use by the hand-held laser welding wand. The mobile
support system is transportable to areas remote from a work shop
environment, and provides stand-alone support for the hand-held
laser welding wand.
Inventors: |
Baker; Martin C.; (Budd
Lake, NJ) ; Taylor; Clyde R.; (Laurens, SC) ;
Hehmann; William F.; (Greer, SC) |
Correspondence
Address: |
HONEYWELL INTERNATIONAL INC.
101 COLUMBIA ROAD, P O BOX 2245
MORRISTOWN
NJ
07962-2245
US
|
Assignee: |
Honeywell International,
Inc.
|
Family ID: |
38309635 |
Appl. No.: |
11/055924 |
Filed: |
February 11, 2005 |
Current U.S.
Class: |
219/121.63 |
Current CPC
Class: |
B23K 37/0294 20130101;
B23K 26/0096 20130101; B23K 26/703 20151001 |
Class at
Publication: |
219/121.63 |
International
Class: |
B23K 26/20 20060101
B23K026/20 |
Claims
1-15. (canceled)
16. The system of claim 25, wherein the enclosure further
comprises: a plurality of panels coupled together to define the
inner volume, at least a portion of the panels being substantially
transparent to visible light and at least partially opaque to
ultraviolet (UV) light and laser light supplied from the laser
source.
17. (canceled)
18. The system of claim 25, further comprising: a fluid circuit
mounted on the cart, the fluid circuit having a fluid flowing
therein that removes heat generated by the laser source; and a heat
exchanger mounted on the cart and having at least a first fluid
flow path and a second fluid flow path, the first fluid flow path
fluidly coupled in series in the first fluid circuit, the second
fluid flow path fluidly coupled to receive a flow of cooling air,
the first heat exchanger adapted to transfer heat between the fluid
in the fluid circuit and the cooling air.
19. The system of claim 18, further comprising: a fan mounted on
the cart and adapted to supply the flow of cooling air to the heat
exchanger second fluid flow path.
20. The system of claim 25, further comprising: a power
distribution module mounted on the cart and electrically coupled to
the laser source and the filler medium supply source, the power
distribution module adapted to receive AC power from an AC power
source and distribute the received AC power to the laser source and
the filler medium supply source.
21. The system of claim 25, wherein the filler medium supply source
includes: a powder feeder; and a wire feeder.
22. The system of claim 25, further comprising: a flexible optical
cable coupled between the laser source and the hand-held laser
welding wand; a flexible fluid conduit coupled between the fluid
source and the hand-held laser welding wand; and a flexible filler
medium conduit coupled between the filler medium supply source and
the hand-held laser welding wand.
23. The system of claim 25, further comprising: an inert gas source
mounted on, or disposed adjacent to, the movable cart, the inert
gas source coupled to the hand-held laser welding wand and
configured to supply a flow of inert gas thereto.
24. The system of claim 25, further comprising: a power supply
configured to generate and supply electrical power, the power
supply adapted to electrically couple to the laser source, the wand
coolant source, and the filler media supply source.
25. A mobile laser welding system, comprising: a cart having a
plurality of wheels rotationally mounted thereon; a laser source
mounted on the cart and configured to supply laser light; a fluid
source mounted on the cart and configured to supply cooling fluid;
a filler medium supply source mounted on the cart and configured to
supply a filler medium; an accessible enclosure mounted on the
movable cart, the enclosure comprising a plurality of panels
coupled together to define an inner volume, the accessible
enclosure including a plurality of glove openings and a sealed
opening; a laser welding wand holder extending from the sealed
opening into the enclosure inner volume; a laser source interlock
coupled to the laser source and configured, upon energization, to
enable laser light emission therefrom; a switch coupled to each of
the panels and configured to close upon its associated panel being
coupled to another panel, each switch electrically coupled in
series with one another between a power source and the laser source
interlock; a plurality of flexible gloves, each glove coupled to,
and configured to seal, one of the glove openings and extend within
the enclosure inner volume; and a laser welding wand configured to
be received in the laser welding wand holder and configured to be
grasped by hand, the wand coupled to receive the laser light from
the laser source, the cooling fluid from the fluid source, and the
filler medium from the filler medium supply source.
Description
TECHNICAL FIELD
[0001] The present invention relates laser welding and, more
particularly, to a mobile hand-held laser welding system.
BACKGROUND
[0002] Many components in a jet engine are designed and
manufactured to withstand relatively high temperatures. Included
among these components are the turbine blades, vanes, and nozzles
that make up the turbine engine section of the jet engine. In many
instances, various types of welding processes are used during the
manufacture of the components, and to repair the components
following a period of usage. In addition, other non-aerospace
applications such as, for example, industrial and commercial
tooling and die maintenance may also benefit from the laser welding
repair process. Moreover, various types of welding technologies and
techniques may be used to implement these various welding
processes. However, one particular type of welding technology that
has found increased usage in recent years is laser welding
technology.
[0003] Laser welding technology uses a high power laser to
manufacture parts, components, subassemblies, and assemblies, and
to repair or dimensionally restore worn or damaged parts,
components, subassemblies, and assemblies. In general, when a laser
welding process is employed, laser light of sufficient intensity to
form a melt pool is directed onto the surface of a metal work
piece, while a filler material, such as powder, wire, or rod, is
introduced into the melt pool. Until recently, such laser welding
processes have been implemented using automated laser welding
machines. These machines are relatively large, and are configured
to run along one or more preprogrammed paths.
[0004] Although programmable laser welding machines, such as that
described above, are generally reliable, these machines do suffer
certain drawbacks. For example, a user may not be able to
manipulate the laser light or work piece, as may be needed, during
the welding process. This can be problematic for weld processes
that involve the repair or manufacture of parts having extensive
curvature and/or irregular or random distributed defect areas.
Thus, in order to repair or manufacture parts of this type, the
Assignee of the present application developed a portable, hand-held
laser welding wand. Among other things, this hand-held laser
welding wand allows independent and manual manipulation of the
laser light, the filler material, and/or the work piece during the
welding process. An exemplary embodiment of the hand-held laser
welding wand is disclosed in U.S. Pat. No. 6,593,540, which is
entitled "Hand Held Powder-Fed Laser Fusion Welding Torch," and the
entirety of which is hereby incorporated by reference.
[0005] The hand-held laser welding wand, such as the one described
above, provides the capability to perform manual 3-D adaptive laser
welding on components. During use, the wand may be coupled to
various support subsystems. For example, the wand may receive laser
light, cooling fluid, filler media, and, in some instances, inert
gas, from appropriate support subsystems. One or more of these
subsystems may be installed in a work shop and not conveniently
transportable. In some instances, welding operations using the
hand-held laser welding wand may need to be performed in areas
remote from a work shop environment. If one or more of the support
subsystems are non-transportable, it may prohibit connecting the
hand-held laser welding wand to the support subsystems, and
potentially prevent its use.
[0006] Hence, there is a need for a support system for the
hand-held laser welding wand that is fully transportable to areas
remote from a work shop environment, so that the hand-held laser
welding wand may be used at a remote work location. The present
invention addresses at least this need.
BRIEF SUMMARY
[0007] The present invention provides a support system for the
hand-held laser welding wand that is fully transportable to areas
remote from a work shop environment.
[0008] In one embodiment, and by way of example only, a mobile
support system for a hand-held laser welding wand includes a
movable cart, a laser source, a fluid source, and a filler medium
supply source. The laser source is mounted on the movable cart and
is configured to supply laser light for the hand-held laser welding
wand. The fluid source is mounted on the movable cart and is
configured to supply cooling fluid for the hand-held laser welding
wand. The filler medium supply source is mounted on the movable
cart and is configured to supply a filler medium for use by the
hand-held laser welding wand.
[0009] In another exemplary embodiment, a mobile laser welding
system includes a movable cart, a laser source, a fluid source, a
filler medium supply source, and a laser welding wand. The laser
source is mounted on the movable cart and is configured to supply
laser light. The fluid source is mounted on the movable cart and is
configured to supply cooling fluid. The filler medium supply source
is mounted on the movable cart and is configured to supply a filler
medium. The laser welding wand is configured to be grasped by hand,
and is coupled to receive the laser light from the laser source,
the cooling fluid from the fluid source, and the filler medium from
the filler medium supply source.
[0010] Other independent features and advantages of the preferred
mobile support system will become apparent from the following
detailed description, taken in conjunction with the accompanying
drawings which illustrate, by way of example, the principles of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a side view of an exemplary hand-held laser
welding wand;
[0012] FIG. 2 is a perspective exploded view of the hand-held laser
welding wand of FIG. 1;
[0013] FIG. 3 is a partial cut-away perspective views of the
hand-held laser welding wand shown in FIGS. 1 and 2;
[0014] FIG. 4 is a simplified schematic representation of a mobile
support system that may be used to provide support to the hand-held
laser welding wand of FIGS. 1-3; and
[0015] FIG. 5 is a perspective view of an enclosure that may be
used with the support system of FIG. 4.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
[0016] The following detailed description of the invention is
merely exemplary in nature and is not intended to limit the
invention or the application and uses of the invention.
Furthermore, there is no intention to be bound by any theory
presented in the preceding background of the invention or the
following detailed description of the invention.
[0017] Turning now to the description, and with reference first to
FIGS. 1-3, an exemplary hand-held laser welding wand 100 is shown,
and includes a main body 102, a nozzle 104, and an end cap 106. The
main body 102, which is preferably configured as a hollow tube,
includes a first end 108 (see FIG. 2), a second end 112, and a
plurality of orifices and flow passages that extend between the
main body first and second ends 108, 112. The orifices and flow
passages are used to direct various fluids and other media through
the main body 102. Included among these media are coolant, such as
water, inert gas, such as Argon, and filler materials, such as
powder, wire, or liquid. These orifices and flow passages are in
fluid communication with orifices and flow passages in the nozzle
104, in the end cap 106, or both. A description of the specific
configuration of each of the orifices and flow paths in the main
body 102 is not needed. Thus, at least the coolant and gas orifices
and flow passages in the main body 102 will not be further
described. The main body filler media orifices and flow passages
will be mentioned further below merely for completeness of
description.
[0018] The nozzle 104 is coupled to the main body first end 108 via
a threaded nozzle retainer ring 202. More specifically, in the
depicted embodiment the main body 102 has a plurality of threads
formed on its outer surface adjacent the main body first end 108.
Similarly, the nozzle retainer ring 202 has a plurality of threads
formed on its inner surface that mate with the main body threads.
Thus, the nozzle 104 is coupled to the main body 102 by abutting
the nozzle 104 against the main body first end 108, sliding the
nozzle retainer ring 202 over the nozzle 104, and threading the
nozzle retainer ring 202 onto the main body 102. It will be
appreciated that the nozzle 104 could be coupled to the main body
first end 108 in a different manner. For example, the nozzle 104
and main body 102 could be configured so that the nozzle 104 is
threaded directly onto the main body first end 108.
[0019] With reference to FIG. 3, it is seen that the nozzle 104
includes an aperture 302 that extends through the nozzle 104. When
the nozzle 104 is coupled to the main body 102, the nozzle aperture
302 is in fluid communication with the inside of the hollow main
body 102. It is through this aperture 302 that laser light and gas
pass during laser welding operations. The nozzle 104 additionally
includes a plurality of filler media flow passages 304. The nozzle
filler media flow passages 304 pass through the nozzle 104 and are
in fluid communication with filler media delivery flow passages 306
that extend through the main body 102. The filler media delivery
flow passages 304, 306 are used to deliver a filler media to a work
piece (not shown).
[0020] The end cap 106 is coupled to the main body second end 112
via a gasket 111 and a plurality of end cap fasteners 208. In
particular, the end cap fasteners 208 extend, one each, through a
plurality of end cap fastener openings 212 (see FIG. 2) formed
through the end cap 106, and into the main body second end 112. In
addition to the end cap fastener openings 212, the end cap 106 also
includes two coolant passages 214, 216, a gas supply passage (not
shown), a plurality of filler media flow passages 218, and a cable
opening 222. The two coolant passages include a coolant supply
passage 214 and a coolant return passage 216. The coolant supply
passage 214, which splits within the end cap 106 into two supply
passages 214a, 214b, directs coolant, such as water, into
appropriate coolant flow passages formed in the main body 102. The
coolant return passage 216, which also splits within the end cap
106 into two return passages 216a, 216b, receives coolant returned
from appropriate coolant flow passages formed in the main body 102.
The non-illustrated gas supply passage directs gas into the main
body 102.
[0021] The end cap filler media flow passages 218 are in fluid
communication with the nozzle filler media flow passages 304 via
the main body filler media flow passages 306. The end cap filler
media passages 218 may be coupled to receive any one of numerous
types of filler media including, but not limited to, powder filler
and wire filler. The filler media may be fed into the end cap
filler media flow passages 218 manually, or the filler media may be
fed automatically from a filler media feed assembly (not shown). In
the depicted embodiment, a plurality of filler media liner tubes
232 is provided. These filler media liner tubes 232 may be
inserted, one each, through one of the end cap filler flow media
passages 218, and into the main body filler media flow passages
306. The filler media liner tubes 232 further guide the filler
media into and through the main body 102, and into the nozzle
filler media flow passages 304. The filler media liner tubes 232
also protect the filler media flow passages against any erosion
that could result from filler media flow through the flow passages.
Although use of the filler media liner tubes 232 is preferred, it
will be appreciated that the wand 100 could be used without the
filler media liner tubes 232.
[0022] The cable opening 222 in the end cap 106 is adapted to
receive an optical cable 236. When the optical cable 236 is
inserted into the cable opening 222, it extends through the end cap
106 and is coupled to a cable receptacle 238 mounted within the
main body 102. The optical cable 236 is used to transmit laser
light from a laser source (not shown) into the main body 102. An
optics assembly 250 is mounted within the main body 102 and is used
to appropriately collimate and focus the laser light transmitted
through the optical cable 236 and receptacle 238, such that the
laser light passes through the nozzle aperture 302 and is focused
on a point in front of the nozzle aperture 302.
[0023] The laser light transmitted through the nozzle aperture 302
is used to conduct various types of welding processes on various
types, shapes, and configurations of work pieces. In many
instances, the work pieces are formed, either in whole or in part,
of various materials that require an inert atmosphere at least near
the weld pool during welding operations. Thus, the hand-held laser
welding wand 100 additionally includes a gas lens assembly 150,
which is mounted on the wand main body 102 and surrounds a portion
of the nozzle 104. The gas lens assembly 150 is adapted to receive
a flow of inert gas from the non-illustrated gas source and is
configured, upon receipt upon receipt of the gas, to develop an
inert gas atmosphere around the weld pool.
[0024] As was just noted, the optical cable 236 transmits laser
light from a laser source for use by the wand 100. In addition,
barbed fittings 224, 226, 228 are coupled to the coolant supply
passage 214, the coolant return passage 216, and the
non-illustrated gas supply passage, respectively, in the end cap
106. These barbed fittings 224, 226, 228 are used to couple the
respective openings to hoses or other flexible conduits that are in
fluid communication with a coolant source or a gas source, as may
be appropriate. It will be appreciated that other types of
fittings, such as compression or threaded fittings, may be
substituted for one or more of the barbed fittings 224, 226, 228,
as needed or desired, based on the particular types of hoses or
conduits used. Moreover, the filler media supply tubes 232 are
preferably in fluid communication with one or more filler media
sources via one or more filler media conduits. The laser source,
the coolant source, the filler media sources and, in some
instances, the gas source, are configured together into a mobile
support system. An embodiment of the mobile support system is
depicted schematically in FIG. 4, and will now be described in more
detail.
[0025] The mobile support system 400 includes a movable cart 402, a
laser source 404, a wand coolant source 406, and a filler media
supply source 408. The movable cart 402 includes a top surface 412,
a bottom surface 414, and a plurality of side walls 416 (only two
shown in FIG. 4) that define an enclosed volume 418. Although not
shown in FIG. 4, one or more of the side walls 416 is preferably
hinged to allow ready access to, and closure of, the enclosed
volume 418. In addition, a plurality of wheels 422 are rotationally
mounted to the cart bottom surface 414. The wheels 422 allow the
cart 402 to be readily moved, by hand or other motive power source,
from place to place. A fan 425 is mounted on one of the cart side
walls 416 and, when energized, supplies a flow of cooling air into
and through the cart inner volume 418.
[0026] In the depicted embodiment, various components, devices, and
subsystems are mounted on the cart top surface 412, while others
are mounted within the cart inner volume 418 or one or on one or
more of the cart side walls 416. It will be appreciated that this
is merely exemplary of a particular mounting arrangement, and that
various other mounting arrangements may be used. It will
additionally be appreciated that the components, devices, and
subsystems that are mounted on or within the movable cart 402 may
vary, but preferably include at least the laser source 404, the
wand coolant source 406, and the filler media supply source 408.
These and various other components, devices, and subsystems will
now be described in more detail.
[0027] The laser source 404 is mounted in the cart inner volume 418
and is configured to supply a source of laser light to the
hand-held laser welding wand 100. As was noted above, and as is
shown in FIG. 4, laser light from the laser source 404 is supplied
to the wand 100 via the optical cable 238. The laser source 404 may
be implemented using any one of numerous known compact, high
efficiency laser sources that supply laser light of sufficient
power to perform laser welding operations. For example, the laser
source 404 may use a diode-pumped fiber laser source or a direct
diode laser source. In one particular embodiment, the laser source
404 is implemented using a YLR-500 diode-pumped multi-mode
Ytterbium (Yb) fiber laser source manufactured by IPG Photonics
Corporation.
[0028] No matter the particular type of laser that is used to
implement the laser source 404, it is preferably disposed within a
cabinet 424 that includes a control panel 426. The control panel
426 includes various types of user interfaces that allow an
operator to control various parameters associated with the laser
source 404. A description of the user interfaces included on the
control panel 426 is not needed, and will therefore not be
provided.
[0029] Preferably, the laser source 404 is controllable using one
or more external control devices 428. To facilitate this, the laser
source 404 also includes at least one external electrical interface
432 that is used to electrically interconnect the laser source 404
and the external control devices 428. It will be appreciated that
the electrical interface 432 could be implemented as a serial or
parallel digital interface, or an analog interface. However, in the
depicted embodiment, the electrical interface 432 is an analog
interface. The external control device 428 includes various user
interfaces that are used to control and monitor the operation of
the laser source 404. The specific user interfaces implemented in
the external control devices 428 may vary, but in the depicted
embodiment include at least a first manual switch 434 that requires
manual manipulation to enable the laser source 404 to emit laser
light, and a second manual switch 436 that varies the power output
of the laser source 404. The manual switches 434, 436 may be
implemented and configured in any one of numerous ways, but in the
depicted embodiment the first switch 434 is implemented as a
hand-actuated switch, and the second switch 436 is implemented as a
foot switch. A description of the remaining user interfaces is not
needed, and will therefore not be described.
[0030] When the laser source 404 is active it will generate heat.
Thus, as FIG. 4 also shows a fluid circuit 438 and a laser heat
exchanger unit 442 are also mounted within the cart inner volume
418. The fluid circuit 438 includes one or more conduits 444, such
as hoses, that are connected between, and used to direct laser
coolant flow through, the laser source 404 and laser heat exchanger
unit 442. The laser coolant Within the fluid circuit 438, which is
preferably water, removes the heat generated by the laser source
404, and flows into and through the laser heat exchanger unit 442,
which in turn removes the heat from the coolant. It will be
appreciated that the laser source 404 may alternatively be
implemented with direct air cooling or an integrated heat
exchanger. In such an alternative implementation, the fluid circuit
438 and laser heat exchanger unit 442 are not included.
[0031] It will be appreciated that the laser heat exchanger unit
442 may be implemented using any one of numerous heat exchanger
configurations. However, in the depicted embodiment the laser heat
exchanger unit 442 is a self-contained water-to-air heat exchanger,
such as the Lytron Model MCS50 manufactured by Lytron Company, of
Woburn, Mass., that includes a coolant reservoir 446, a coolant
pump 448, a heat exchanger 452, and a fan 454. The coolant
reservoir 446 stores a volume of laser coolant (e.g., water), and
the coolant pump 448, when energized, circulates the laser coolant
through the fluid circuit 438.
[0032] The heat exchanger 452, as is generally known, includes two
fluid flow paths, a first fluid flow path 456 and a second fluid
flow path 458. The first fluid flow path 456 is fluidly coupled in
series in the fluid circuit 438, and the second fluid flow path 458
is fluidly coupled to receive a flow of cooling air that is
supplied by the fan 454. Thus, as the coolant flows through the
heat exchanger first flow path 456, it is cooled by the cooling air
supplied from the fan 454 that flows through the second flow path
458.
[0033] In the depicted embodiment, the support system 400 further
includes a temperature sensor 462 that senses coolant temperature
in the fluid circuit 438. The temperature sensor 462 may be used
for any one of numerous purposes and functions, but in the depicted
embodiment it is used to supply a signal to an indicator circuit
464 that will activate an audible warning indicator 466 if the
coolant temperature reaches or exceeds a predetermined set point.
It will be appreciated that the temperature sensor 462, if
included, may be disposed to sense coolant temperature at any one
of numerous positions in the fluid circuit 438; however, in the
depicted embodiment the temperature sensor 462 is disposed to sense
the temperature of the coolant exiting the heat exchanger 452.
[0034] It will be appreciated that the fluid circuit 438 could
additionally supply a flow of coolant to the hand-held laser
welding wand 100 to remove heat therefrom. However, the laser
source 404 can operate at relatively high temperatures, and as such
the coolant within the fluid circuit 438 may not sufficiently cool
the wand 100 to a desired temperature. Thus, in the depicted
embodiment, a separately controllable wand coolant source 406 is
provided, and will now be described in more detail.
[0035] The wand coolant source 406 is also mounted in the cart
inner volume 418 and is configured to circulate a coolant through
the welding wand 100. As was noted above, coolant is supplied to,
and flows through, the welding wand 100 to reduce the temperature
of the main body 102 to desired value. To do so, the wand coolant
source 406 is coupled to the welding wand 100 via a pair of
flexible conduits 468, 472, and is preferably a self-contained unit
that includes a coolant reservoir 474, a pump 476, and a
refrigeration unit 478. The reservoir 474 stores a volume of wand
coolant, such as water, and the pump 476, when energized,
circulates the wand coolant through the welding wand 100 via the
coolant supply conduit 468 and the coolant return conduit 472.
[0036] As the wand coolant flows through the welding wand main body
102, it cools the main body 102 to a comfortable temperature. The
heat that is transferred from the main body 102 to the wand coolant
is then removed by the refrigeration unit 478. The coolant source
406 is preferably controllable, so that an operator can select a
desired temperature to which to cool the wand 100. Preferably, the
coolant source 406 should allow the temperature to be set and
controlled to a temperature that is sufficiently cool to allow an
operator to hold the wand 100, yet not so cool that condensation
could potentially form on or within the wand 100. An exemplary
physical implementation of the coolant source 406 described herein
is a VWR Model 1162A manufactured by VWR International, of West
Chester, Pa. It will be appreciated, however, that the wand coolant
source 406 could be implemented using any one of numerous devices
and in any one of numerous configurations.
[0037] Turning now to the filler media supply source 408, this
subsystem is mounted on the cart top surface 412 and is configured
to supply filler media to the hand-held laser welding wand 100. The
filler media supply source 408 may supply any one of numerous types
of filler media to the welding wand 100. In the depicted
embodiment, the filler media supply source 408 is implemented using
both a wire feeder 482 and a powder feeder 484. The wire feeder 482
is used to supply wire-type welding filler media to the welding
wand 100, and may be implemented using any one of numerous types of
wire feeders. In a particular physical implementation, the wire
feeder 482 is implemented using a Model WF-3 Wire Feeder,
manufactured by CK Worldwide, Inc., of Auburn, Wash. The powder
feeder 484 is used to supply powder-type welding filler media to
the welding wand 100, and may also be implemented using any one of
numerous types of powder feeders. In a particular physical
implementation, the powder feeder 484 is implemented using a
compact, pressurized, adjustable screw-driven unit, manufactured by
Honeywell International, Inc of Morristown, N.J.
[0038] In one embodiment, the filler media supply source 408 is
controlled, in an on/off fashion, via a foot switch 486. Thus, when
an operator using the welding wand 100 desires filler media to be
supplied to the wand 100, the user presses the foot switch 486,
which in turn causes the filler media supply source 408 to supply
the filler media to the welding wand 100. The filler media supply
source 408 includes one or more interfaces 488, which are used to
interconnect the foot switch 486 and the filler media supply source
408. The rate at which the filler media supply source 408 supplies
the filler media to the welding wand 100 is preferably set using a
control 492 on the filler media supply source 408. It will
nonetheless be appreciated that this function could be implemented
in any one of numerous other ways.
[0039] No matter the particular type or number of devices that are
used to implement the filler media supply source 408, a filler
media conduit 494 is coupled between the filler media supply source
408 and the wand 100, to supply the desired filler media thereto.
More specifically, as was noted above, the filler media conduit 494
is preferably coupled at one end to the filler media supply source
408, and at another end to one of the filler media supply tubes 232
that is inserted through the end cap 106 and into the main body
102.
[0040] In addition to each of the above-described subsystems and
components, the mobile support system 400 preferably includes an
enclosure 450 and may optionally include an inert gas source 496.
The enclosure 450, which is shown more clearly in FIG. 5, includes
a plurality of panels 502a-e that are coupled together to define an
inner work volume 504 on the cart top surface 412. It will be
appreciated that the panels 502a-e may be constructed of any one of
numerous materials and in any one of numerous configurations.
However, in a particular preferred embodiment, the panels 502a-e
are each constructed of substantially transparent plastic that is
laminated with a laser-absorbing acrylic material in a surrounding
aluminum frame 506.
[0041] The acrylic laminated plastic is a preferable since this
provides panels 502a-e that are substantially transparent to
visible light, yet sufficiently attenuate the laser light emitted
from the laser welding wand 100. In the depicted embodiment, the
side panels 502a-d and the top panel 502e are each constructed of
the acrylic laminated transparent plastic. However, it will be
appreciated that not all of these panels need be transparent.
Moreover, in the depicted embodiment a separate non-laminated panel
is used for the bottom surface (not depicted) of the enclosure 450,
though it will be appreciated that a laminated panel could be
used.
[0042] As FIG. 5 also shows, at least some of the panels 502a-e
have releasable retainer clips 508 coupled thereto. These clips 508
are used to couple the panels 502a-e together to form the enclosure
450. It will be appreciated that, for clarity and ease of
illustration, only three releasable retainer clips 508 are shown.
Nonetheless, the releasable retainer clips 508 are preferable since
these allow the enclosure 450 to be readily assembled and
disassembled and removed from the cart 402 for storage. It will
nonetheless be appreciated that the panels 502a-e could be coupled
together using any one of numerous devices, and in any one of
numerous configurations. Moreover, it is preferable that the
enclosure 450, when assembled, is relatively leak tight. Thus, a
seal (not shown) is preferably disposed at the interface of each
panel 502a-e. In addition, each panel 502a-e preferably includes an
interlock contact closure switch 451 (see FIG. 4) that closes when
the panel 502a-e is securely in place. The switches are
electrically coupled in series with a master laser interlock (not
shown), which inhibits laser emission until all of the closure
switches 451 are closed.
[0043] The inner work volume 504 may be used to conduct various
welding operations on small parts or for welding specialized
materials using the hand-held laser welding wand 100. Thus, the
enclosure 450 further includes a wand interface 512 and at least
two glove openings 514. The wand interface 512 includes a sealed
opening 516 that extends through the enclosure top panel 502e. A
flexible bellows 518 extends downward from the sealed opening 516
toward the cart top surface 412 and provides both a light and a gas
tight seal. As FIG. 4 illustrates, the hand-held laser welding wand
100 may be inserted into and partially through the flexible bellows
518 to facilitate laser welding operations within the inner work
volume 504. As was described above, and will be further elaborated
upon below, inert gas may be supplied to the welding wand 100 to
create an inert gas atmosphere at least adjacent the nozzle 104. It
will be appreciated that the inert gas that is supplied to the
welding wand 100 also desirably creates an inert gas atmosphere
within the inner work volume 504.
[0044] The two glove openings 514 extend through the enclosure
front panel 502. A flexible glove 522 is coupled to, and seals,
each of the glove openings 514. The flexible gloves 522, which are
preferably formed of rubber or other suitably flexible material,
are coupled to the glove openings 514 such that the hand openings
for each glove 522 are external to the inner work volume 504. Thus,
an operator can insert both hands into the gloves 522 to manipulate
both the part being worked on and the laser welding wand 100. It
will be appreciated that the size and weight of the enclosure 450
may vary, depending on its configuration and material make-up.
However, in a particular physical implementation, the assembled
enclosure 450 is 37''.times.32''.times.25'' and weighs
approximately 80 pounds.
[0045] It will be appreciated that in some instances it may be
necessary or desirable to operate the hand-held laser welding wand
100 outside of the enclosure 450. In such instances, the wand 100
and interconnecting conduits are removed from the enclosure 450 and
operated externally thereof. It will be appreciated that in such
instances one or more interlock provisions and/or barriers may be
needed, as well as additional personal protective equipment for the
operator and/or other individuals in the vicinity of the work
area.
[0046] Returning once again to FIG. 4, it was previously noted that
the support system 400 may additionally include the inert gas
source 496. In the depicted embodiment, the inert gas source 496 is
included, and is mounted on a base 498 that is coupled to the cart
402. It will be appreciated, however, that the inert gas source 496
could be included as a component separate from the cart 402, or an
on-site inert gas source (not shown) could be used. Nonetheless, as
FIG. 4 shows, and as was described briefly above, in the depicted
embodiment the inert gas source 496 supplies inert shield gas to
the welding wand 100 via a flexible conduit 499.
[0047] The laser source 404, the wand coolant source 406, the
filler media supply source 408, and the laser heat exchanger unit
442 all operate on electrical power. In the depicted embodiment,
the wand coolant source 406, the filler media supply source 408,
the laser heat exchanger unit 442, and the cart fan 425 operate on
120 VAC electrical power, and the laser source 404 operates on 220
VAC electrical power. The electrical power for each of these
subsystems may be supplied from on-site power sources, from a
portable generator 410, or both. Preferably, the portable generator
is configured to supply both 120 VAC and 220 VAC electrical
power.
[0048] No matter the particular source of electrical power, the
cart 402 preferably includes a power distribution module 420 that
receives the 120 VAC from the source, and distributes the 120 VAC
to the wand coolant source 406, the filler media supply source 408,
the laser heat exchanger unit 442, and the cart fan 425 via
appropriate wiring. The 220 VAC is supplied directly to the laser
source 404 via a separate connector (not shown).
[0049] As FIG. 4 also shows, the support system 400 may also be
connected to a remote control console 430. The remote control
console 430, if included, is configured to implement the functions
of the first switch 434, the second switch 436, and the filler
media foot switch 486 in a single user interface device. A
description of the remote control console 430 is not needed, and
will therefore not be provided.
[0050] The support system 400 for described herein is transportable
to areas remote from a work shop environment, and provides
stand-alone support for the hand-held laser welding wand 100. The
size and weight of the transportable cart 402 may vary, depending
upon the support subsystems that are mounted on it. However, in a
particular physical implementation, in which the enclosure 450 is
not mounted thereon, and at least the laser source 404, the wand
coolant source 406, the filler media supply source 408, the fluid
circuit 438, the laser heat exchanger 442, and the power
distribution module 420 and associated wiring are mounted thereon,
the cart 402 is about 48-inches long, 33-inches deep, and 60-inches
high (including the height of the filler media supply source 408),
and weighs about 950 pounds.
[0051] While the invention has been described with reference to a
preferred embodiment, it will be understood by those skilled in the
art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope
of the invention. In addition, many modifications may be made to
adapt to a particular situation or material to the teachings of the
invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the
particular embodiment disclosed as the best mode contemplated for
carrying out this invention, but that the invention will include
all embodiments falling within the scope of the appended
claims.
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